Active monitoring of alignment of rig component

ABSTRACT

A tool for use in subterranean operations can include a top drive and an alignment sensor coupled to the top drive. The alignment sensor can measure an alignment condition of a first rig component relative to an alignment position. A system for wellbore operations can include the tool and generate an alarm signal upon misalignment of rig components prior to damage of the equipment.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Patent Application No.62/186,866, filed Jun. 30, 2015, entitled “Active Monitoring ofAlignment of Rig Component”, naming as an inventor Scott Boone, whichapplication is incorporated by reference herein in its entirety.

FIELD OF DISCLOSURE

The present disclosure relates generally to wellbore drillingoperations, and more particularly to measuring an alignment condition ofa rig component.

BACKGROUND

Drilling subterranean wells for oil and gas is expensive and timeconsuming. Formations containing oil and gas are typically locatedthousands of feet below the earth's surface. To access the oil and gas,thousands of feet of rock and other geological formations must beremoved. To ensure a cost-effective drilling operation, equipmentutilized in wellbore drilling operations must be capable of repeated,reliable operation. Damage to components of a drilling rig due tomisalignment in the wellbore can cause equipment to fail and can shutdown an operation, rendering the drilling operation economicallyunsustainable. The industry continues to demand improvements insubterranean drilling operations.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited in theaccompanying figures.

FIG. 1 includes a schematic view of a drilling rig.

FIG. 2 includes a partially cut away front perspective view of ajunction box disposed on a top drive in accordance with an embodiment.

FIG. 3 includes a side perspective view of FIG. 2.

FIG. 4 includes a simplified schematic of an active sensing andcontinuous (real time) information relaying operation adapted to senseand actively relay an alignment condition in accordance with anembodiment.

Skilled artisans appreciate that elements in the figures are illustratedfor simplicity and clarity and have not necessarily been drawn to scale.For example, the dimensions of some of the elements in the figures maybe exaggerated relative to other elements to help to improveunderstanding of embodiments of the invention.

DETAILED DESCRIPTION

The following description in combination with the figures is provided toassist in understanding the teachings disclosed herein. The followingdiscussion will focus on specific implementations and embodiments of theteachings. This focus is provided to assist in describing the teachingsand should not be interpreted as a limitation on the scope orapplicability of the teachings. However, other embodiments can be usedbased on the teachings as disclosed in this application.

The terms “comprises,” “comprising,” “includes,” “including,” “has,”“having” or any other variation thereof, are intended to cover anon-exclusive inclusion. For example, a method, article, or apparatusthat comprises a list of features is not necessarily limited only tothose features but may include other features not expressly listed orinherent to such method, article, or apparatus. Further, unlessexpressly stated to the contrary, “or” refers to an inclusive-or and notto an exclusive-or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or notpresent), A is false (or not present) and B is true (or present), andboth A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one, at least one, or the singular as alsoincluding the plural, or vice versa, unless it is clear that it is meantotherwise. For example, when a single item is described herein, morethan one item may be used in place of a single item. Similarly, wheremore than one item is described herein, a single item may be substitutedfor that more than one item.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The materials, methods, andexamples are illustrative only and not intended to be limiting. To theextent not described herein, many details regarding specific materialsand processing acts are conventional and may be found in textbooks andother sources within the drilling arts.

The concepts are better understood in view of the embodiments describedbelow that illustrate and do not limit the scope of the presentinvention. The following description includes a tool for wellboreoperations. Certain embodiments of the tool can include a sensor adaptedto measure an alignment condition of a rig component. The alignmentcondition can include the relationship between the actual position ofthe rig component and its alignment position. As used herein, the term“alignment position” refers to a reference position used to determinethe alignment of the rig component and will be discussed in more detailbelow. In certain embodiments, the tool can measure the alignmentcondition continuously (in real-time) and relay the condition to a user.Further, the description includes a system for use in subterraneanoperations. The system can include a sensor and a computing system incommunication with the alignment sensor to determine, for example,adjustments to the rig component based on its alignment condition.Furthermore, the description includes a method of operating a system forsubterranean operations. The method can include acquiring an alignmentcondition and adjusting a rig component to change the alignmentcondition of the rig component.

The term “alignment condition” refers to the alignment status of the rigcomponent based on the proximity of the rig component to its alignmentposition. In certain embodiments, the alignment condition can include atleast an aligned condition, where the proximity of the rig component toits alignment position is within an acceptable range, and a misalignedcondition, where the proximity of the rig component to its alignmentposition is outside of an acceptable range.

In certain embodiments, the proximity of the rig component to itsalignment position can include the angle of departure of the actualposition of the rig component from the alignment position. For example,sensing and generating data regarding an alignment condition can includemeasuring an angle of departure of the actual position of the rigcomponent (or an axis of the rig component) from an alignment position.In particular embodiments, the angle of departure can include a pitchangle, a roll angle, or both. In further embodiments, the tool can besensitive enough to comply with the engineered tolerances of the machinebeing used. For example, the angle of departure can be measured at aninterval sensitivity of at least 0.1°, at least 0.01°, or at least0.001°.

The smaller the angle of departure, the closer the rig component is toits alignment position. For example, the actual position of the rigcomponent can approach an aligned alignment condition as the angle ofdeparture approaches 0°. In certain embodiments, the alignment conditionincludes an aligned alignment condition when the angle of departure isno greater than 5°, no greater than 1°, no greater than 0.5°, or even nogreater than 0.1°.

Conversely, the larger the angle of departure, the farther the rigcomponent is from its alignment position. For example, the actualposition of the rig component can approach a misaligned alignmentcondition when the angle of departure moves away from 0°. In certainembodiments, the alignment condition includes a misaligned alignmentcondition when the angle of departure is at least 0.1°, at least 0.5°,at least 1°, or even at least 5°.

As stated previously, an alignment position is a reference position usedin determining the alignment condition of the rig component. In certainembodiments, the alignment position can include at least one axis, atleast two axes, or even at least three axes. For example, the alignmentposition can include a uniaxial alignment position including a firstaxis. As another example, the alignment position can include a biaxialalignment position including a first axis and a second axis. In any typeof alignment position, one or more of the at least one axis can includea predetermined axis.

In certain embodiments, the alignment position can include a first axisand a second axis where the first axis and the second axis are differentcompared to each other. In particular embodiments, the first axis can beorthogonal to the second axis. For example, in any type of alignment,the first axis can include true vertical or true horizontal. Thus, in abiaxial alignment position, the first axis can include true vertical andthe second axis can include true horizontal, and vice versa. Further,instead of true vertical or true horizontal, in any type of alignmentthe first axis or second axis can be greater than 0° from true verticalor from true horizontal, such as greater than 0° and less than 90° fromtrue vertical or from true horizontal. Furthermore, in any type ofalignment position, the first axis or second axis can include an axis ofa second rig component. The second rig component can include, forexample, a top drive, guide tracks a top drive, running gear disposed ona top drive, or any combination thereof. Also, the second rig componentcan include a quill, a drill string or at least a portion of a drillstring, such as a top portion of a drill string.

In accordance with an embodiment of the present invention, FIG. 1 is asimplified schematic of a subterranean drilling operation 100. Thedrilling rig 100 can be an offshore drilling rig or a land baseddrilling rig. Offshore drilling rigs can take many forms. For example,the drilling rig 100 can have a fixed platform or substructure attachedto an underlying seabed. Alternatively, the drilling rig 100 can includea floating platform disposed at least partially underwater with ananchoring system holding the drilling rig 100 relatively near theunderwater drilling operation. It should be understood that theparticular configuration and embodiment of the drilling rig 100 are notintended to limit the scope of the present disclosure.

As illustrated in FIG. 1, the drilling rig 100 can generally include asubstructure 102 and a derrick 104. The derrick 104 can be attached tothe substructure 102 and can extend therefrom. The derrick 104 can be atower or a guyed mast such as a pole which can be hinged at a bottomend. The derrick 104 and substructure 102 can be permanent or can beadapted to break down for transportation. In certain embodiments, thedrilling rig 100 can further include a hoisting system 106, a top drive108, and a power supply 110. While a top drive 108 is shown, theprinciples of this disclosure can apply to any drive system including atop drive, a power swivel or a rotary table. The derrick 104 can supportthe hoisting system 106 and the top drive 108. In a particularembodiment, the hoisting system 106 can include a drawworks 114 and ablock and tackle system 116 adapted to support a drill string 118.

Typically, a top drive is suspended from the derrick and is connected toa drill string via a main drive shaft (a short section of pipe known asa quill). The top drive rotates the quill which, in turn, rotates thedrill string and the drill bit to produce a well bore. A misalignment ofthe top drive and the drill string can result in damage to the quill,which can cause equipment to fail and can shut down an operation. Manualalignment of the top drive and the drill string relative to an alignmentposition, such as true vertical, has proven to be either inaccurate orunable to account for misalignments that occur during operation. Forexample, the top drive can be suspended in the derrick by a travelingblock that allows the top drive to move up and down the derrick wheremisalignment can occur. Further, mobile drill rigs have been developedthat are capable of “walking” about a location and such movements arecapable of resulting in a misalignment. Even when stationary, rigfoundations can shift or settle. Such movement can result in amisalignment that occurs during operation that can damage rigcomponents, such as the top drive or the drill string. Properorientation should be monitored during operation to assist in realigningthe mast sections or the top drive and avoiding damage to the rigcomponents.

In a particular aspect, at least one alignment sensor 200 (see FIG. 4)can be coupled to an equipment of the drilling rig 100 to actively senseand generate data regarding an alignment condition of a rig componentrelative to an alignment position. As used herein, “actively sense”refers to an act of sensing where a sensing condition occurs at leastonce every hour, such as at least once every 30 minutes, at least onceevery minute, or even at least once every 10 seconds. In a particularembodiment, “actively sense” refers to an act of sensing wherein asensing condition occurs at least 1 time per minute (TPM), such as atleast 30 TPM, at least 60 TPM, at least 120 TPM, or even at least 300TPM. Moreover, in particular embodiments, the alignment sensors cansense the condition no greater than 5,000 TPM, such as no greater than4,000 TPM, no greater than 3,000 TPM, no greater than 1,000 TPM, nogreater than 500 TPM, or even no greater than 300 TPM.

The alignment sensor should be disposed in a location that allows thealignment sensor to measure the alignment condition. For example, the atleast one alignment sensor 200 can be coupled to the top drive 108, orintegrated into a remote panel on the top drive 108, such as in thejunction box 120 illustrated in FIGS. 2 and 3. FIG. 2 includes a frontview of the junction box 120 relative to an x-axis and FIG. 3 includes aside view of the junction box 120 relative to a y-axis along the sameplane as the x-axis. Further, the alignment sensor can be disposed in afixed position on the top drive. The alignment sensor can be fixed invarious ways including adhering the alignment sensor to the top drive.From the top drive, the alignment sensor can track the alignmentcondition (as discussed previously) to determine, for example, themisalignment of the top drive relative to the mast.

In certain embodiments, the alignment sensor can include an alignmentsensor that can measure the angle of inclination of a rig component. Forexample, the alignment sensor can include an inclinometer. In particularembodiments, the inclinometer can include a microelectromechanicalsystem (MEMS) or a nanoelectomechanical system (NEMS). In moreparticular embodiments, the inclinometer can include a dual axisinclinometer. The dual axis inclinometer can be configured to measurepitch and roll inclination. In further embodiments, the inclinometer caninclude a bubble inclinometer.

In addition, the alignment sensor can include a linear alignmentindicator. For example, the linear alignment indicator can include alaser alignment system. In certain embodiments, a laser alignment headcan be coupled to a rig component, such as the top drive. The laseralignment head can direct a laser to a desired target indicating analignment condition based on whether the laser engages with the target.In embodiments, the target can include a visual target where a userdetermines alignment based on visual perception of whether the laserengages the target. In other embodiments, the target can include asensor target that can determine whether the laser engages the targetwithout the visual perception of a user. In particular embodiments, thelinear alignment indicator can be used in combination with the sensormeasuring the angle of inclination. For example, the linear alignmentindicator can measure offset alignment and the inclination sensor canmeasure angular alignment.

In certain embodiments, the data from the alignment sensor, including analignment condition of a rig component, can be transmitted, such astransmitted to a computing system. The data can be transmitted to assistin realignment of the rig components. As discussed in more detail below,the computing system can display the alignment condition on ahuman-machine interface (HMI), and the HMI can display the alignmentcondition using adjustable models of the rig components or otherindicators of the alignment condition.

In certain embodiments, the alignment sensor 200 can be disposed outsidea housing, or in communication with an intermediary member disposedoutside of the housing by electrical wiring extending through thehousing or a wireless signal. In this regard, the alignment sensor 200can communicate the sensed alignment condition to an intermediary memberlocated outside of the housing of the equipment. In another embodiment,the alignment sensors 200 can be directly engaged with a logic element202, independent of an intermediary member. The logic element 202 may bedisposed immediately proximate to the alignment sensors.

In a non-limiting embodiment, it may be advantageous to position atleast a portion of each alignment sensor 200 at a location whereby thealignment sensor 200 can be reached and affected from an exteriorlocation of the equipment. In another non-limiting embodiment, thealignment sensor 200 can be coupled to a portion of the equipment thatcan be readily removed or opened in order to expose the alignmentsensor, e.g., a sealable hatch or access point. In such a manner, thealignment sensor 200 can be manipulated, adjusted, or even replacedwithout requiring significant operation upon the equipment.

Referring now to FIG. 4, during drilling operations, one or morealignment sensors 200 can actively monitor an alignment condition of thefirst rig component. For example, the alignment sensor can be monitoredas part of a rig control system. After being collected by the alignmentsensors 200, a sensed data relating to the alignment condition of thefirst rig component can be transferred (illustrated by line 208)continuously (in real time) to a logic element 202. As used herein“transferred continuously” refers to a transmission of data at leastonce every hour, such as at least once every 30 minutes, at least onceevery minute, or even at least once every 10 seconds. In a particularembodiment, “transferred continuously” refers to a transmission of dataat least once every 30 minutes. In yet a more particular embodiment,“transferred continuously” refers to the transmission of data as it isobtained at each sensed interval, i.e., data is immediately transferredfrom the alignment sensors to the logic element. In a particularembodiment, a memory storage unit can be attached to the alignmentsensors 200 for the temporary storage of the sensed data prior totransfer. The memory storage unit can further include a back up powersupply.

In certain embodiments, the sensed data can be transferred to the logicelement 202 as one or more data streams over a network or other wirelesssignal. The data can be transmitted within a working environmentincluding the drilling rig. In addition, in certain embodiments, aremote communication element can relay the sensed data, such as througha satellite relay system, to a remote geographic location, disposed at alocation different than the drill rig. In a particular embodiment, thetransfer format and protocol can be based on the industry WITSML format,which uses XML as a data format and web services over HTTPS as aprotocol. In another embodiment, the sensed data can be transferreddirectly to the logic element 202 by wiring or by another non-wirelesslocal communication system, such as a LAN network. In such a manner, thelogic element 202 can be disposed at a location on, or proximate to, thedrill rig. In yet another embodiment, the logic element can include aplurality of interconnected logic elements. The interconnected logicelements can all be disposed at a single location or at separationlocations interconnected by network or wireless signal.

In a particular embodiment, the logic element 202 can include aprogrammable logic controller, such as computer software. The logicelement 202 can be adapted to receive a signal generated by thealignment sensor 200, the signal containing sensed data regarding thealignment condition of the first rig component.

Utilizing the data contained in the signal, the logic element 202 canperform a calculation and generate an alarm signal when the sensedalignment condition deviates from an accepted value by more than 5%,such as when the condition deviates from the accepted value by more than10%, or even when the condition deviates from the accepted value by morethan 15%. The alarm signal can indicate to a user or drilling engineerthat the alignment condition, such as the angle of departure, of thefirst rig component is outside of an acceptable range of the acceptedvalue. For example, the data from the alignment sensor can betransmitted to assist a rig crew to realign either the mast sections orthe top drive (as will be discussed in more detail below).

In a particular embodiment, the accepted value can be programmed by auser, i.e., a user can formulate an acceptable value for the measuredconditions and set the accepted value accordingly in the logic element.Moreover, the value for the angle of departure can be custom selectedbased on operational factors. In this regard, a user can adjust thedeviation calculation based on environmental factors or risk assessment.For example, in harsh climates, e.g., deep water, dessert, or tropicallocations, a lower deviation (e.g., 1° from alignment position) can beutilized as the alarm generating condition. In less risk averse drillingoperations, e.g., small scale on-land operations, a higher deviation(e.g., 5° from alignment position) can be utilized as the alarmgenerating condition. In such a manner, risk can be assessed andaddressed on a per operation manner.

In another embodiment, the accepted value can be set by one or more ofthe previously sensed conditions, e.g., the accepted value can bedetermined based on a previously sensed value of the condition. Forexample, the accepted value can be determined by a first value sensed bythe alignment sensor, to which all future deviations are measured andcompared against. If a later sensed value deviates from the initiallyallotted value to a degree beyond the allotted deviation, an alarmsignal can be generated.

After performing an analysis of the sensed condition, the logic element202 can communicate (illustrated by lines 210) a signal to an interface204. The interface 204 can include a user interface adapted to displaythe signal from the logic element 202. In this regard, a user canvisually determine the alignment condition (pitch and roll angle) of therig component. In another embodiment, the logic element 202 can transferthe signal to an interface 206 located at the drill site.

In certain embodiments, the interface 204 can display to a user one oftwo indications: an indication that the sensed condition of thealignment condition is within the acceptable range (i.e., aligned); oran indication that the sensed alignment condition is outside of theacceptable range (i.e., misaligned). A third indication may optionallyindicate to the user that the alignment condition is approaching thelimits of acceptable deviation, i.e., the rig components may need to berealigned soon. Furthermore, in certain embodiments, the interface 204can display a series of escalating alerts depending on the alignmentcondition.

In certain embodiments, the interface 204 can provide a real-timenumerical visualization of the sensed alignment condition of the rigcomponent. In this regard, the interface 204 may further include avisualization tool including graphical comparisons through time-indexedgraphs. The visualization tool may be capable of illustratingqualitative parameter values, trends, interpreted activities,interesting events, etc. for the purpose of enhancing overall operation.For example, in particular embodiments, the alignment sensormeasurements can be monitored by a computer versus time and its positionin the mast of the rig. In addition, models of the adjustable sectionsof rig, such as the mast, the top drive, and the top drive supportsystem, can be used to help direct the rig crew on how to adjust variousrig components to achieve an aligned alignment condition. Additionally,in certain embodiments, the computing system can adjust a misaligned rigcomponent based on the data received from the alignment sensor,including the alignment condition of the rig component.

In the case of a rapid fluctuation of the sensed alignment condition, avisualization tool may not be sufficient to rapidly alert of impendingmisalignment causing damage to the rig components. In this regard, incertain embodiments it may be desirable to include an indicator toindicate whether the alignment condition of the rig component is withinor outside of the acceptable range.

The interface 204 can additionally include a data analysis server.Drilling engineers and other users and operators can use a clientapplication running a personal computer or other computing device toconnect from the drilling rig site or an operations center to the dataanalysis server in order to receive and display the sensed data. Onceconnected, the client application can be continuously updated withinformation from the data analysis server until such a time as theclient is closed. In a particular embodiment, the data analysis servercan be a program written in a Java programming language. The preferredclient application can also be a Java application. The protocol betweenthe client application and the server application can be based onregular polling by the client application using an HTTP or HTTPS(secured) connection.

A memory element can be positioned to interact with one or more of thelogic element, the interface, or the data analysis server, and recordand store historical valuation calculations for future analysis andreview. The memory element can be disposed at a location proximate tothe drill rig, the logic element, the interface, the data analysisserver, or any other suitable location. The memory element canoptionally contain a programmable software adapted to erase storedrecorded data after a threshold period, e.g., every six months, in orderto reduce required storage capacity.

Further, the various measurements between components may be correct butthe system may detect that the rig foundation has actually settled andthe entire rig must be realigned, such as realigned relative tovertical. The alignment sensor measurements can also be used to helpmaintain the guide tracks and running gear on the top drive. The systemcan also be used to measure drifting or “crabbing” of the top drive asit moves throughout the mast. All of this can be used to align the rigcomponents at the initial construction of the rig, at beginning of a newwellbore, or during operation at an existing wellbore.

In a certain embodiment, the system for wellbore operations can furtherinclude a stop element adapted to permit a user to terminate drillingoperations in the case of an emergency. The stop element can be handledby an operator located at the interface. In this regard, any activedrilling operations can be shut down remotely and a service crew can bedispatched to the drill site.

As discussed previously, the alignment sensor can be part of a systemfor use in subterranean operations. The system can comprise the topdrive, the alignment sensor, and the computing system as describedabove. The alignment sensor can measure and transmit an alignmentcondition of a rig component and the computing system can receive thesensor data including an alignment condition and determine adjustmentsto the rig component. As discussed above, the computing system canadjust the rig component based on the alignment condition. For example,the computing system can generate a re-alignment signal to one or moreadjustment mechanisms on at least a portion of a derrick. Further, thecomputing system can actuate at least a portion of the derrick andchange the alignment of the first rig component relative to thealignment position. In particular embodiments, the computing system caninclude an actuator configured to mechanically change the tilt angle ofa rig component, such as the derrick, in at least one axis.

Further, a method of operating a system for subterranean operations caninclude providing a drill rig, establishing a first alignment position,acquiring sensor data regarding the alignment condition of a rigcomponent, and adjusting the rig component to an aligned alignmentcondition. In certain embodiments, the method can include adjusting therig component occurs during installation of the rig, during a drillingoperation, or continuously throughout the drilling operation. Asdiscussed above, the adjusting can be done remotely. Alternatively, theadjusting can be performed manually and the adjusting can be performedfree of a manual level.

Many different aspects and embodiments are possible. Some of thoseaspects and embodiments are described below. After reading thisspecification, skilled artisans will appreciate that those aspects andembodiments are illustrative and do not limit the scope of the presentinvention. Embodiments may be in accordance with any one or more of theembodiments as listed below.

LIST OF EMBODIMENTS Embodiment 1

A tool for use in subterranean operations, comprising:

a top drive; and

an alignment sensor coupled to the top drive;

wherein the alignment sensor is configured to measure an alignmentcondition of a first rig component relative to an alignment position.

Embodiment 2

The tool of Embodiment 1, wherein the alignment position includes afirst axis, a second axis, or both and the first and second axis aredifferent compared to each other.

Embodiment 3

The tool of Embodiment 2, wherein the first axis is orthogonal to thesecond axis.

Embodiment 4

The tool of any one of Embodiments 2 and 3, wherein the first axisincludes true vertical.

Embodiment 5

The tool of any one of Embodiments 2-4, wherein the first axis has anangle of departure from true vertical that is greater than 0° and lessthan 90°.

Embodiment 6

The tool of any one of Embodiments 2-4, wherein the second axis includestrue horizontal.

Embodiment 7

The tool of any one of Embodiments 2-4, wherein the second axis has anangle of departure from true horizontal that is greater than 0° and lessthan 90°.

Embodiment 8

The tool of any one of Embodiments 2-7, wherein the first axis, thesecond axis, or both include an axis of a drill rig component.

Embodiment 9

The tool of Embodiment 8, wherein the drill rig component includes aquill disposed between the top drive and a drill string.

Embodiment 10

The tool of Embodiment 8, wherein the drill rig component includes thetop drive, guide tracks disposed on the top drive, running gear disposedon the top drive, or any combination thereof.

Embodiment 11

The tool of Embodiment 8, wherein the drill rig component includes aportion of a drill string.

Embodiment 12

The tool of Embodiment 11, wherein the drill rig component includes atop portion of the drill string.

Embodiment 13

The tool of any one of the preceding Embodiments, wherein the top driveis disposed in a derrick tower.

Embodiment 14

The tool of Embodiment 13, wherein the drill rig component includes asupport structure of the derrick tower.

Embodiment 15

The tool of Embodiment 10, wherein the derrick tower is a walkingderrick tower.

Embodiment 16

The tool of any one of the preceding Embodiments, wherein measuring analignment condition includes measuring an angle of departure from thealignment position.

Embodiment 17

The tool of Embodiment 16, wherein the alignment condition includes anormal alignment when the angle of departure from the alignment positionis no greater than 5°, no greater than 1°, no greater than 0.5°, or nogreater than 0.1°.

Embodiment 18

The tool of Embodiment any one of Embodiments 16 and 17, wherein thealignment condition includes a misalignment when the angle of departurefrom the alignment position is at least 0.1°, at least 0.5°, at least1°, or at least 5°.

Embodiment 19

The tool of any one of Embodiments 16 and 18, wherein the angle ofdeparture includes a pitch angle, a roll angle, or a combinationthereof.

Embodiment 20

The tool of any one of Embodiments 16-19, wherein the angle of departureis measured at an interval sensitivity of at least 0.1°, at least 0.01°,or at least 0.001°.

Embodiment 21

The tool of any one of the preceding Embodiments, wherein the top driveis coupled to a mast and the alignment sensor is further configured todetect drifting of the top drive as it moves through the mast.

Embodiment 22

The tool of any one of the preceding Embodiments, wherein the alignmentsensor includes an inclinometer.

Embodiment 23

The tool of Embodiment 22, wherein the inclinometer includes amicroelectromechanical system (MEMS).

Embodiment 24

The tool of Embodiment 22, wherein the inclinometer includes ananoelectomechanical system (NEMS).

Embodiment 25

The tool of any one of Embodiments 22-24, wherein the inclinometerincludes a dual axis inclinometer.

Embodiment 26

The tool of any one of Embodiments 24, wherein the dual axisinclinometer is configured to measure pitch and roll inclination.

Embodiment 27

The tool of Embodiment 22, wherein the inclinometer includes a bubbleinclinometer.

Embodiment 28

The tool of any one of the preceding Embodiments, wherein the alignmentsensor includes a laser alignment system.

Embodiment 29

The tool of any one of the preceding Embodiments, wherein the alignmentsensor is adapted to be monitored in a rig control system.

Embodiment 30

The tool of any one of the preceding Embodiments, wherein the alignmentsensor is coupled to a fixed position on the top drive.

Embodiment 31

The tool of any one of the preceding Embodiments, wherein the alignmentsensor is integrated into a remote panel on the top drive.

Embodiment 32

The tool of any one of the preceding Embodiments, wherein the alignmentsensor is disposed in a fixed position on the top drive.

Embodiment 33

The tool of Embodiment 32, wherein the alignment sensor is adhered tothe top drive.

Embodiment 34

The tool of any one of the preceding Embodiments, wherein the alignmentcondition is configured to be transmitted to a computing system.

Embodiment 35

The tool of Embodiment 34, wherein the computing system is configured todisplay the alignment condition on a human-machine interface.

Embodiment 36

The tool of Embodiment 35, wherein the human-machine interface isconfigured to display the alignment condition using models of adjustablesections of a mast, the top drive, a top drive support structure, or anentire rig.

Embodiment 37

The tool of any one of Embodiments 34-36, wherein computing system isconfigured to adjust the rig component based on the alignment condition.

Embodiment 38

The tool of any one of Embodiments 34-37, wherein computing system isconfigured to display realignment instructions based on the alignmentcondition.

Embodiment 39

The tool of any one of the preceding Embodiments, wherein the alignmentsensor is configured to generate a signal indicating the alignmentcondition.

Embodiment 40

The tool of Embodiment 39, wherein the signal includes at least one of asignal indicating an aligned condition and a signal indicating amisaligned condition.

Embodiment 41

The tool of Embodiment 40, wherein the signal indicating the alertcondition includes a series of escalating alerts depending on thealignment condition.

Embodiment 42

The tool of any one of Embodiments 39-41, wherein the signal istransmitted within a working environment.

Embodiment 43

The tool of any one of Embodiments 39-41, wherein the signal istransmitted to a remote monitoring environment.

Embodiment 44

A system for use in subterranean operations comprising:

-   -   a top drive;    -   an alignment sensor coupled to the top drive, the alignment        sensor configured to measure and transmit an alignment condition        of a first rig component relative to an alignment position; and

a computing system in communication with the alignment sensor, thecomputing system configured to receive the alignment condition from thealignment sensor and determine adjustments to the rig component based onthe alignment condition

Embodiment 45

The system of Embodiment 44, wherein computing system is configured todisplay the alignment information on a human-machine interface.

Embodiment 46

The system of Embodiment 44, wherein the human-machine interface isconfigured to display the alignment condition using models of adjustablesections of a mast, the top drive, a top drive support structure, or anentire rig.

Embodiment 47

The system of any one of Embodiments 44-46, wherein computing system isconfigured to adjust the rig component based on the alignment condition.

Embodiment 48

The system of any one of Embodiments 44-47, wherein the computing systemis configured to generate a re-alignment signal to one or moreadjustment mechanisms on at least a portion of a derrick.

Embodiment 49

The system of Embodiment 48, wherein the one or more adjustmentmechanisms is configured to actuate at least a portion of the derrickand change the alignment of the first rig component relative to thealignment position.

Embodiment 50

The system of any one of Embodiments 48-49, wherein the one or moreadjustment mechanisms includes an actuator configured to mechanicallychange the tilt angle of the derrick in at least one axis.

Embodiment 51

A method of operating a system for subterranean operations comprising:

-   -   providing a drill rig and establishing a first alignment        position, wherein the drill rig includes a top drive and an        alignment sensor coupled to the top drive;    -   acquiring an alignment condition of a first rig component        relative to an alignment position; and

adjusting the first rig component to change the alignment condition thefirst rig component relative to the alignment position

Embodiment 52

The method of Embodiment 51, wherein the drill rig includes a walkingdrill rig.

Embodiment 53

The method of any one of Embodiments 51 and 52, wherein adjusting thefirst rig component occurs during installation of the rig.

Embodiment 54

The method of any one of Embodiments 51-53, wherein adjusting the firstrig component occurs during a drilling operation.

Embodiment 55

The method of any one of Embodiments 54, wherein adjusting the first rigcomponent occurs continuously throughout the drilling operation.

Embodiment 56

The method of any one of Embodiments 51-55, wherein adjusting the firstrig component occurs manually.

Embodiment 57

The method of any one of Embodiments 51-55, wherein adjusting the firstrig component occurs free of a manual level.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

After reading the specification, skilled artisans will appreciate thatcertain features are, for clarity, described herein in the context ofseparate embodiments, may also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, may also be providedseparately or in any subcombination. Further, references to valuesstated in ranges include each and every value within that range.

The embodiments provide a combination of features, which can be combinedin various matters to describe and define a method and system of theembodiments. The description is not intended to set forth a hierarchy offeatures, but different features that can be combined in one or moremanners to define the invention. In the foregoing, reference to specificembodiments and the connection of certain components is illustrative. Itwill be appreciated that reference to components as being coupled orconnected is intended to disclose either direct connected between saidcomponents or indirect connection through one or more interveningcomponents as will be appreciated to carry out the methods as discussedherein.

As such, the above-disclosed subject matter is to be consideredillustrative, and not restrictive, and the appended claims are intendedto cover all such modifications, enhancements, and other embodiments,which fall within the true scope of the present invention. Thus, to themaximum extent allowed by law, the scope of the present invention is tobe determined by the broadest permissible interpretation of thefollowing claims and their equivalents, and shall not be restricted orlimited by the foregoing detailed description.

The disclosure is submitted with the understanding that it will not beused to interpret or limit the scope or meaning of the claims. Inaddition, in the foregoing disclosure, various features may be groupedtogether or described in a single embodiment for the purpose ofstreamlining the disclosure. This disclosure is not to be interpreted asreflecting an intention that the embodiments herein limit the featuresprovided in the claims, and moreover, any of the features describedherein can be combined together to describe the inventive subjectmatter. Still, inventive subject matter may be directed to less than allfeatures of any of the disclosed embodiments.

What is claimed is:
 1. A tool for use in subterranean operations,comprising: a top drive; and an alignment sensor coupled to the topdrive; wherein the alignment sensor is configured to measure analignment condition of a first rig component relative to an alignmentposition.
 2. The tool of claim 1, wherein the alignment positionincludes a first axis, a second axis, or both and the first and secondaxis are orthogonal compared to each other.
 3. The tool of claim 1,wherein measuring an alignment condition includes measuring an angle ofdeparture from the alignment position.
 4. The tool of claim 3, whereinthe alignment condition includes a normal alignment when the angle ofdeparture from the alignment position is no greater than 5°, no greaterthan 1°, no greater than 0.5°, or no greater than 0.1°.
 5. The tool ofclaim 3, wherein the alignment condition includes a misalignment whenthe angle of departure from the alignment position is at least 0.1°, atleast 0.5°, at least 1°, or at least 5°.
 6. The tool of claim 3, whereinthe angle of departure includes a pitch angle, a roll angle, or acombination thereof.
 7. The tool of claim 3, wherein the angle ofdeparture is measured at an interval sensitivity of at least 0.1°, atleast 0.01°, or at least 0.001°.
 8. The tool of claim 1, wherein the topdrive is coupled to a mast and the alignment sensor is furtherconfigured to detect drifting of the top drive as it moves through themast.
 9. The tool of claim 1, wherein the alignment sensor includes aninclinometer.
 10. The tool of claim 9, wherein the inclinometer includesa microelectromechanical system (MEMS) or a nanoelectomechanical system(NEMS).
 11. The tool of claim 9, wherein the inclinometer includes adual axis inclinometer configured to measure pitch and roll inclination.12. The tool of claim 1, wherein the alignment sensor is adapted to bemonitored in a rig control system.
 13. The tool of claim 1, wherein thealignment sensor is coupled to a fixed position on the top drive. 14.The tool of claim 13, wherein the alignment sensor is adhered to the topdrive.
 15. The tool of claim 1, wherein the alignment sensor isintegrated into a remote panel on the top drive.
 16. The tool of claim1, wherein the alignment condition is configured to be transmitted to acomputing system.
 17. The tool of claim 16, wherein the computing systemis configured to display the alignment condition on a human-machineinterface and display the alignment condition using models of adjustablesections of a mast, the top drive, a top drive support structure, or anentire rig.
 18. The tool of claim 16, wherein the computing system isconfigured to adjust the rig component based on the alignment condition,display realignment instructions based on the alignment condition, orboth.
 19. A system for use in subterranean operations comprising: a topdrive; an alignment sensor coupled to the top drive, the alignmentsensor configured to measure and transmit an alignment condition of afirst rig component relative to an alignment position; and a computingsystem in communication with the alignment sensor, the computing systemconfigured to receive the alignment condition from the alignment sensorand determine adjustments to the rig component based on the alignmentcondition.
 20. A method of operating a system for subterraneanoperations comprising: providing a drill rig and establishing a firstalignment position, wherein the drill rig includes a top drive and analignment sensor coupled to the top drive; acquiring an alignmentcondition of a first rig component relative to an alignment position;and adjusting the first rig component to change the alignment conditionthe first rig component relative to the alignment position.